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S4179694

Air Purging

Air and moisture in the refrigerant system may have

undesirable effects as indicated below.

●

pressure in the system rises

●

operating current rises

●

cooling (or heating) efficiency drops

●

moisture in the refrigerant circuit may freeze and

block capillary tubing

●

water may lead to corrosion of parts in the refriger-

ant system

Therefore, the indoor unit and tubing between the

indoor and outdoor unit must be leak tested and

evacuated to remove any noncondensables and

moisture from the system.

■

Air Purging with a Vacuum Pump (for Test Run)

Preparation

Check that each tube (both narrow and wide) between

the indoor and outdoor units have been properly

connected and all wiring for the test run has been

completed. Remove the valve caps from both the wide

and narrow service valves on the outdoor unit. Note

that both narrow and wide tube service valves on the

outdoor unit are kept closed at this stage.

Leak test

(1)

With the service valves on the outdoor unit closed,

remove the 1/4 in. flare nut and its bonnet on the

wide tube service valve. (Save them for reuse.)

(2)

Attach a manifold valve (with pressure gauges)

and dry nitrogen gas cylinder to this service port

with charge hoses.

Use a manifold valve for air

purging. If It is not available,

use a stop valve for this

purpose. The “Hi” knob of

the manifold valve must

always be kept closed.

(3)

Pressurize the system to no more than 150

P.S.I.G. with dry nitrogen gas and close the

cylinder valve when the gauge reading reaches

150 P.S.I.G. Then, test for leaks with liquid soap.

Cap

Narrow tube

Wide tube

Manifold valve

Pressure
gauge

Nitrogen gas
cylinder

1370_C_I

Fig. 9-1

Fig. 9-2

Manifold valve

Pressure
gauge

Charge hose

Outdoor unit

Service
valve

Wide tube

Narrow
tube

Indoor unit

Nitrogen gas cylinder
(In vertical standing
position)

1369_C_I

3-way valve is used for 3632 type.

CAUTION

Содержание C2432A

Страница 1: ...STALL THE REMOTE CONTROL UNIT 33 Wireless Remote Control Unit 4 1 Mounting on a Wall except KS2432A 4 2 Mounting on a Wall KS2432A only Wired Remote Control Unit Option except 2432A 4 3 Installing the Wired Remote Control Unit CONTENTS Split System Air Conditioner 85464359249001 5 ADDRESS SWITCHES except KS2432A 36 5 1 Finding the Address Switches 5 2 Switch Positions for 2 Units or 2 Groups of Un...

Страница 2: ...Read Before Starting This air conditioning system meets strict safety and operating standards As the installer or service person it is an important part of your job to install or service the system so it operates safely and efficiently For safe installation and trouble free operation you must ⓦ Carefully read this instruction booklet before beginning ⓦ Follow each installation or repair step exact...

Страница 3: ... and insulation Consult your nearest sales outlet or A C workshop for KS2432A For rear left tubing optional tube connection C APR EN46U1B is necessary See page 30 Also consult your nearest sales outlet or A C workshop 1 4 Type of Copper Tube and Insulation Material If you wish to purchase these materials separately from a local source you will need 1 Deoxidized annealed copper tube for refrigerant...

Страница 4: ...t For wide flare joints For ends of flare insulator For determining suspension bolt pitch For sealing recessed portion of power supply Table 1 1 XS Recessed Part Name Figure Q ty Remarks Full scale installation diagram 1 Flare insulator 1 Installation gauge 1 Insulating tape 1 Hose band 2 Packing 1 Drain insulator 1 Drain hose 1 Drain hose adapter 1 Owner s manual 1 For determining suspension bolt...

Страница 5: ... mm 1 Part Name Figure Q ty Remarks Wall fixture 1 1 Insulator 1 1 Mounting plate 1 1 Tapping screw 1 20 Full scale diagram 1 Wall fixture 2 1 Rawl plug 2 10 Cover 2 1 Tapping screw 2 10 Insulator 2 1 Owner s manual 1 1 KS3032 KS3632 only 2 KS2432 only Table 1 3 2 KS Wall Mounted KS2432A only Truss head Phillips 5 32 5 8 4 16 mm Part Name Figure Q ty Remarks Tube Assy 1 Packing A 1 Packing B 1 Cla...

Страница 6: ...Fig 1 1 No additional charge of compressor oil is necessary 1 If total tubing length becomes 50 to 132 ft charge additional refrigerant R22 by 0 27 oz ft 2 If total tubing length becomes 50 to 165 ft charge additional refrigerant R22 by 0 86 oz ft 3 When either outdoor unit C2432A or CL2432A is combined with indoor unit KS2432A and total tubing length becomes 25 to 50 ft charge additional refriger...

Страница 7: ...elect a location where tubing and drain pipe have the shortest run to the outdoor unit allow room for operation and maintenance as well as unrestricted air flow around the unit install the unit within the maximum elevation difference above or below the outdoor unit and within a total tubing length from the outdoor unit as detailed in Table 1 6 allow room for mounting the remote control unit about ...

Страница 8: ...ltiple installations Fig 2 1 Fig 2 2 Min 1 inch Min 1 inch Min 2 ft 4 in 0931_C_I Min 7 ft Ground Air dis charge 0932_C_I Obstacle above Unit spacing if air discharge chamber is not used Unit spacing when air discharge chamber is used Min 4 ft Min 4 ft Min 5 ft Min 1 ft Min 12 ft Min 8 inch Min 4 ft Min 8 inch Min 4 ft Min 1 ft 2 inch Min 1 ft 2 inch Min 1 ft Min 1 ft Air discharge chamber If you ...

Страница 9: ...ature in winter wind shield must be installed on the outdoor unit This unit is designed so that the fan of the outdoor unit runs at low speed when the air conditioner is operated at low outdoor air temperatures When the outdoor unit is exposed to strong wind the system pressure drops because of the freeze protector For outer dimensions of wind shield please see Fig 2 6 Air discharge 0426_C_I Impor...

Страница 10: ... ensures that the unit will be securely and safely suspended 2 Follow Fig 3 2 and Table 3 1 to make the holes in the ceiling 3 Determine the pitch of the suspension bolts using the supplied full scale installation diagram The diagram and table Fig 3 3 and Table 3 2 show the relationship between the positions of the suspension fitting the unit and the panel A Ceiling opening B Suspention bolt pitch...

Страница 11: ...on bolt must be appropri ate for a distance between the bottom of the bolt and the bottom of the ceiling of more than 2 3 8 in as shown in Fig 3 4 3 Thread the 2 hexagonal nuts and washers field supply onto the 4 suspension bolts as shown in Fig 3 5 Use 2 sets of nuts and washers upper and lower so that the unit will not fall off the suspen sion lugs 4 Remove the protective cardboard used to prote...

Страница 12: ...m of 10 in Do not raise it any higher than 10 in as this could result in water leaks Fig 3 9 Do not install the pipe with an upward gradient from the connection port It will cause the drain water to flow backwards and leak when the unit is stopped Fig 3 10 Do not apply force to the piping on the unit side when connecting the drain pipe The pipe should not be allowed to hang unsupported from its co...

Страница 13: ...er into the drain pan to check drainage 2 Do Test Run to check the drainage after complet ing installation When performing Test Run be sure to observe the Test Run procedure Refer to page 46 Be careful since the fan will start turning when checking the drainage 3 After drain checking is finished return the Operation Selector switch to the RUN position ON position and remount the tube cover To moun...

Страница 14: ...el 1 Remove the air intake grille and air filter from the ceiling panel Figs 3 13 and 3 14 a Remove the 2 screws on the latch of the air intake grille Fig 3 13 b Press on the 2 latches of the air intake grille with your thumb in the direction of the arrow to open the grille Fig 3 13 c With the air intake grille open about 45 remove the safety string hook on the grille side Fig 3 14 d Pull the air ...

Страница 15: ...connector from the ceiling panel to the connector in the electrical component box of the indoor unit After installing the connector use the clamp on the body of the indoor unit to secure the wiring Fig 3 15 NOTE 0967_X_I Ceiling panel Ceiling panel Mark Screws M5 with washer Ceiling panel wiring connector Air filter Air intake grille Panel catch pull down Connector on unit inside electrical compon...

Страница 16: ...igh performance filter open the lid of the electrical component box remove the socket 9P of the fan motor cable inside the electrical component box and connect the accessory cord with socket 9P 3 9 Duct for Fresh Air Air intake chamber including Duct connection box and flange are attached to the indoor unit when used to take fresh outdoor air High performance filter or Super long life filter can b...

Страница 17: ...3P plug of the indoor unit electrical component box Connect the 6P socket to the 6P plug from the operation selector Reattach the socket cover f INSTALLING THE HIGH PERFORMANCE FILTER OR SUPER LONG LIFE FILTER Fig 3 18 Turn the filter hooks of the air intake chamber Install high performance or super long life filter into the chamber Install in the correct direction Set the filter so that the arrow...

Страница 18: ... existing ceiling supports or construct a suitable support as shown in Fig 3 21 It is important that you use extreme care in supporting the indoor unit from the ceiling Enure that the ceiling is sufficiently strong enough to support the weight of the unit Before hanging the ceiling unit test the strength of each attached suspension bolt 4 Screw in the suspension bolts allowing them to protrude fro...

Страница 19: ...eiling or not Fig 3 25 and 3 26 7 Suspend the indoor unit as follows a mount a washer and two hexagonal nuts on each suspension bolt as shown in Fig 3 27 Fig 3 23 Slide toward front side Side panel 0972_T_I Fig 3 24 unit Suspension bolt field supply Ceiling surface Washer supplied Double nut field supply Fixture 0974_T_I Fig 3 25 unit Suspension bolt field supply Washer supplied Washer field suppl...

Страница 20: ... panel and the ceiling surface and fill the gap with an appropriate insulation or filler material 8 If the tubing and wiring are to go towards the rear of the unit make holes in the wall Fig 3 30 9 Measure the thickness of the wall from the inside to the outside and cut PVC pipe at a slight angle to fit Insert the PVC pipe in the wall Fig 3 31 Fig 3 28 0979_T_I 0978_T_I Fig 3 29 NOTE The hole shou...

Страница 21: ...the course of the piping Insulate any piping inside the room to prevent dripping Use the supplied drain pipe to connect the drain pipe with the drain outlet of the indoor unit After connecting the drain pipe securely wrap the supplied drain pipe insulator around the pipe seal the gap at the drain socket with the supplied black insulation tape then secure it with clamps Fig 3 35 After the drain pip...

Страница 22: ...ey hole saw or 3 5 32 in hole cutting drill attachment make a hole in the wall The required minimum hole diameter for these models is 3 3 16 in Fig 3 38 4 Measure the thickness of the wall from the inside edge to the outside edge and cut PVC pipe at a slight angle 1 4 in shorter than the thickness of the wall Fig 3 39 5 Place the plastic cover over the end of the pipe for indoor side only and inse...

Страница 23: ...goes through a wall at any other location 4 Using a sabre saw key hole saw or 3 5 32 in hole cutting drill attachment make a hole in the wall The required minimum hole diameter for these models is 3 3 16 in Fig 3 42 5 Measure the thickness of the wall from the inside edge to the outside edge and cut PVC pipe at a slight angle 1 4 in shorter than the thickness of the wall Fig 3 43 6 Place the plast...

Страница 24: ...in dia holes in the wall Insert rawl plugs for appropriate mounting screws Fig 3 46 Confirm that the wall is strong enough to support the unit a If the Wall is Wooden 1 Attach the wall fixture to the wall with the 12 screws provided Fig 3 47 If you are not able to line up the holes in the wall fixture with the beam locations marked on the wall use rawl plugs or toggle bolts to go through the holes...

Страница 25: ..._I Fig 3 48 Plastic cover Screw 0945_T_I Clamp Screw 0946_T_I KS2432 KS3032 KS3632 NOTE Air intake grille Grille 2242_T_I Air intake grille 2243_T_I Fig 3 52 Fig 3 53 3 17 Removing the Grille to Install the Indoor Unit Basically this model can be installed and wired with out removing the grille If access to any internal part is needed follow the steps as given below How to remove the grille 1 Set ...

Страница 26: ...ut the left tubing outlet Fig 3 57 Arrangement for Right Tubing a Cut out the right tubing outlet using a hacksaw Fig 3 58 Arrangement for Left rear and Right rear Tubing a It is not necessary to cut a hole 2244_T_I 2245_T_I Left rear tubing Left tubing Right rear tubing Recommended Right tubing 0949_T_I 0951_T_I Right tubing outlet 0950_T_I Left tubing outlet Fig 3 57 Fig 3 58 Fig 3 56 KS2432 KS2...

Страница 27: ...e 1361_T_I Indoor unit Bottom cover Left side cover Right side cover 3 19 Wiring Instructions General Precautions on Wiring 1 Before wiring confirm the rated voltage of the unit as shown on its name plate then carry out the wiring closely following the wiring diagram 2 Provide a power outlet to be used exclusively for each unit a power supply disconnect and circuit breaker for overcurrent protecti...

Страница 28: ...nter unit wiring to the corresponding terminals on the terminal plate Fig 66 67 while referring to the wiring diagram 4 Be sure to secure the wiring with the provided clamp How to remove the cover plate To access the terminal plate inside the indoor unit follow these steps 1 Using a Phillips screwdriver take out the screw on the cover plate Fig 66 67 2 Remove the cover plate KS2432A Wall Plastic c...

Страница 29: ...wiring from the outdoor unit to the corresponding terminals on the terminal plate Be sure to refer to the wiring system diagram label inside the metallic cover and carry out the correct field wiring Wrong wiring can cause the unit to malfunction Check local electrical codes and any specified wiring instructions or limitations e Secure the metallic cover with its screw Then replace the side cover K...

Страница 30: ... Fig 3 73 Also refer to Section 8 5 Connecting Tubing between Indoor and Outdoor Units 5 Assemble the refrigerant tubing drain hose and inter unit wiring as shown in Fig 3 74 Pipe bending tool a b b a 0 7 or more 2249_T_I Fig 3 72 Fig 3 71 Fig 3 73 0955_T_I Insulating tape 0969_T_I Refrigerant tubing Narrow tube Wide tube Inter unit wiring Drain hose C type Without insulation on the narrow tube 09...

Страница 31: ... contact of the tube assy with the mounting valve Fig 3 78 3 79 4 Similarly arrange the supplied packing B 2 3 8 1 3 16 T3 16 on the mounting valve Fig 3 78 3 79 5 Insert clamp Ain the extracted round hole 3 16 on the mounting valve and bind the tube assy and packing A Fig 3 78 6 Insert clamp B in the square hole of the mounting valve and bind it so the tube assy is in contact with packing B Fig 3...

Страница 32: ...e wall The plate can be positioned in either of the 2 ways shown Fig 3 83 Fig 3 82 1366_T_I Wall Wall fixture Indoor unit Fig 3 81 1365_T_I Narrow tube Drain hose Fig 3 83 1367_T_I Mounting plate Screws Or 3 22 Installing the Drain Hose a The drain hose should be slanted downward on the outdoor side Fig 3 84 b Never form a trap in the course of the hose c If the drain hose will run in the room ins...

Страница 33: ...firming correct operation use a screwdriver to screw the supplied special mounting screw into the wall Fig 4 1 4 Hang the remote control unit from the mounting screw b Non removable mounting 1 Momentarily hold the remote control unit in the desired mounting position 2 Confirm that the air conditioner responds correctly when you press keys on the remote control from that position 3 After confirming...

Страница 34: ...not place objects that may block the transmitted signals between the receiver and the remote control unit b Non removable mounting 1 Mount the holder to the wall with one of the screws using only the hole in the top of the holder Fig 4 4 2 Remove the cover of the remote control unit and take out the batteries Next place the remote control unit in the holder 3 Fasten both the remote control unit an...

Страница 35: ...r similar pointed object to remove the plastic bushing which is inserted in the rear of the remote control unit The bushing can be discarded Fig 4 6 2 Align the cord with the groove of the remote control unit 3 Attach the mounting plate to the wall with the 2 supplied screws Then align the rail on the rear of the control unit with the slot of the mounting plate and slide the unit down as far as it...

Страница 36: ...Power Switch b Remove the Grille c Remove the cover of the Electrical Component Box d Remove the P C B by pressing the head of each spacer and pull the P C B up for wall mounted type only e Pull out the P C B to access the address switch Fig 5 2 for wall mounted type only 5 2 Switch Positions for 2 Units or 2 Groups of Units Table 5 1 shows the positions you can use for up to 2 units or 2 groups o...

Страница 37: ...3 Service valves are housed inside the unit To access them remove the access panel by remov ing the 3 attaching screws then slide the panel downward and pull it toward you If either rear right or front tubing is needed punch out the knockout holes with a hammer or similar tool After punching out the knockout holes mount plastic protectors on the tubing outlets There accessories are packed inside t...

Страница 38: ...s with all relevant rules and regulations 8 To prevent malfunction of the air conditioner caused by electrical noise care must be taken when wiring as follows The inter unit control wiring and the remote control wiring option should be wired apart from the inter unit power wiring It is recommended that shielding wires or twisted pair wires be used for the remote control and the inter unit control ...

Страница 39: ...r or any moving part To avoid the risk of electric shock each air conditioner unit must be grounded Be sure to connect the power supply line to the outdoor unit as shown in the wiring diagram The indoor unit draws its power from the outdoor unit CAUTION Problem 1 Short circuit will occur after approx 3 minutes Problem 2 Air conditioner will not operate Problem 3 Compressor will not start only indo...

Страница 40: ...id wire to form a loop suitable for the terminal screw 4 Shape the wire loop properly position it on the terminal plate and fix it securely with the terminal screw using a screwdriver For stranded wiring 1 Cut the wire end with a wire cutter or wire cutting pliers then strip the insulation to expose the stranded wiring about 3 8 in Fig 7 2 2 Using a Pillips head screwdriver remove the terminal scr...

Страница 41: ...he copper tube 4 Make a flare at the end of copper tube with a flare tool Fig 8 3 Use RIGID or equivalent A good flare should have the following characteristics inside surface is glossy and smooth edge is smooth tapered sides are of uniform length 8 3 Precaution before Connecting Tubes Tightly 1 Apply a sealing cap or water proof tape to pre vent dust or water from entering the tubes before they a...

Страница 42: ...Table 8 1 Tightening Torque Approx 140 180 kg cm 120 160 Ibs in Approx 340 420 kg cm 300 360 lbs in Approx 1000 1200 kg cm 870 1040 lbs in Tube Dia 1 4 6 35 mm 3 8 9 52 mm 3 4 19 05 mm Unit side insulator Insulation tape white supplied Seal supplied Flare insulator supplied Tube insulator not supplied Vinyl clamps supplied Flare nut 1015_X_I 8 6 Insulating the Refrigerant Tubing Always insulate tu...

Страница 43: ...from the bottom of the outdoor unit to the top of the tubing where it enters the wall As you wrap the tubing overlap half of each previous tape turn Fig 8 10 3 Clamp the tubing bundle to the wall using 1 clamp about every 3 feet Do not wind the armoring tape too tightly since this will decrease the heat insulation effect Also ensure that the condensation drain hose splits away from the bundle and ...

Страница 44: ... both narrow and wide tube service valves on the outdoor unit are kept closed at this stage Leak test 1 With the service valves on the outdoor unit closed remove the 1 4 in flare nut and its bonnet on the wide tube service valve Save them for reuse 2 Attach a manifold valve with pressure gauges and dry nitrogen gas cylinder to this service port with charge hoses Use a manifold valve for air purgin...

Страница 45: ...cylinder Evacuation 1 Attach the charge hose end described in the preceding steps to the vacuum pump to evacuate the tubing and indoor unit Confirm that the Lo knob of the manifold valve is open Then run the vacuum pump The operation time for evacuation varies with the tubing length and capacity of the pump The following table shows the amount of time for evacuation The required time in the above ...

Страница 46: ...urned all the way out BACK SEAT position 3 Loosen the charge hose connected to the wide tube service port 1 4 in slightly to release the pressure then remove the hose 4 Replace the 1 4 in flare nut and its bonnet on the wide tube service port and fasten the flare nut securely with an adjustable wrench or box wrench This process is very important to prevent gas from leaking from the system 5 Replac...

Страница 47: ...peration selector Flap 0985_M_I Fig 10 2 10 2 Performing Test Run Be careful since the fan will start when performing Test Run 1 For TS and XS models the Operation Selector is located on the electrical component box inside the indoor unit To access the Operation Selector press the two latches of the air intake grille in the direction of the arrow to open the grille Open the air intake grille downw...

Страница 48: ... start running 3 minutes after the ON OFF operation button is pressed 4 Let the unit run for about 30 minutes and check that it operates normally 5 Press the ON OFF operation button again to stop the unit Set the Service Test RUN switch at RUN position otherwise the unit will not run correctly Important Fig 10 3 Fig 10 4 Power mains switch Connected ON 0559_C_I Fig 10 5 Service TEST RUN switch RUN...

Страница 49: ...n Narrow Tube Service Wide Tube Service Valve 3 Way Valve Ball Valve CLOSED CLOSED Shipping and air purging Fully Fully OPEN OPEN Operating and test running the air conditioner Half Fully OPEN OPEN Measuring pressure and gas charging 0548_C_I O ring Valve cap 0989_C_I Stem Stem Valve cap O ring 1372_C_I 2 Way Valve C2432A CL2432A 3 Way Valve C3032A CL3032A C3632A CL3632A C4232A CL4232A ...

Страница 50: ...he manifold valve to the service port B on the wide tube service valve 2 Using a hex wrench turn the narrow tube service valve clockwise all the way to close the service valve 3 Press the operation button and start cooling operation 4 When the low pressure gauge reading falls to 1 to 0 5 kg cm2 14 2 to 7 1 psi fully close the wide tube valve stem with a standard screwdriver Then quickly stop the u...

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